Beam shaping BrightLine Weld: latest application results

Feuchtenbeiner, S.; Dubitzky, Wilrid; Hesse, Tim; Speker, Nicolai; Haug, Patrick; Seebach, J.; Hermani, Jan-Patrick; Havrilla, David

doi:10.1117/12.2509560

Cited by 10 publications

(6 citation statements)

References 3 publications

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“…It can also be noted that the height measurement distributes more widely for the beam shape C and this was quantified by the interquartile range, presented in Figure 9. It can be seen that beam shapes TE, LE and DE, all produced reinforcement height with lower interquartile range than that produced by beam shape C. This indicates that more stable process conditions can be achieved by shaping the beam, as concluded by previous research [16] [3]. It is also interesting to notice that the interquartile range of the height measurement is strongly correlated with the weld pool rear curvature angle.…”

Section: Weld Pool Top Surface Visualization and Measurementsupporting

confidence: 63%

Impact of laser beam shaping on weld pool and seam geometry in butt-joint welding with filler wire

Mi,

Sikström,

Nilsen

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Beam shaping offers a promising solution to address various challenges in laser-based processes. This study explores the use of an adaptive beam shaping solution using a deformable mirror for high-power continuous wave lasers. Specifically, the impact of three different elliptical beam shapes on weld pool geometry, weld cross section in butt-joint welding with a filler wire is investigated. The results reveal that beam shaping significantly affects the weld pool and cross section, with elliptical beam shapes resulting in wider fusion zones in two tested cases and more uniform weld bead compared to a typical circular beam. These findings highlight the potential of beam shaping for enhancing consistency and quality in laser beam welding.

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Section: Weld Pool Top Surface Visualization and Measurementsupporting

confidence: 63%

Impact of laser beam shaping on weld pool and seam geometry in butt-joint welding with filler wire

Mi,

Sikström,

Nilsen

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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“…The evaporation pressure then leads to a widening of the keyhole. This expansion moves in the direction of the keyhole bottom (2)(3)(4)(5). When it reaches the bottom of the keyhole, a bubble is formed.…”

Section: Analysis Of Pore Formationmentioning

confidence: 99%

“…The analysis and avoidance of both welding failures are part of current research. One option for improving the weld seam quality is using a ring mode laser [1][2][3] . In addition to the gaussian center beam, it has a ring-shaped intensity distribution.…”

Section: Introductionmentioning

confidence: 99%

Influence of ring-shaped laser beam during welding of AW-5083 and AW-6082

Hollatz

Hummel

Lach

et al. 2023

High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XII

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The ongoing development of lasers with integrated beam-shaping features offers new opportunities for research in the field of laser beam welding. Main challenges for laser welding of aluminum alloys, such as AW-5083 or AW-6082, are pore formation and cracking. The locally adapted power distribution has a major influence on the keyhole required for deep penetration welding and therefore on occurring weld defects. To determine the reasons, the use of synchrotron radiation during the welding process enables the visibility of the keyhole shape. This investigation contains an analysis of the keyhole and melt pool shape based on the high-speed video images of the synchrotron radiation. The variation of the power ratio of center beam to ring allows a comparison of the influence of the beam shaping method. To stabilize the keyhole, a temporal power modulation is used for the ring. The results show an influence of the ring mode on the keyhole depth and the melt pool shape. The videos allow an analysis of different mechanisms for pore formation, such as the collapse of the keyhole.

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“…To some extent, this has already been addressed by many Laser and machine manufacturers by implementing galvo-scanners in their processing heads for fast beam steering [3] but coming at a larger footprint due to the size of the galvo actuators. Additionally, beam shaping technologies to create intensity distributions differing from a Gaussian-like focal spot have been demonstrated improving the process outcome as it could be shown by Trumpf (Brightline) [4], Amada (Ventis) [5], N-light (Corona) [6] or "ARM"-technology available from Coherent [7], where the output from a multi-clad optical fiber is used to tailor the intensity distribution depending on the power fraction in the individual sections of the fiber with shape shifting times in the range of several milliseconds (< 1 kHz). To the best of our knowledge, none of these systems provide comprehensive process monitoring in combination with online process control that directly influences the relevant process parameters such as laser power, feed rate and intensity distribution.…”

Section: Introductionmentioning

confidence: 99%

Design of a processing-head for AI-optimized welding and cutting

Strecker,

Böttner,

Yildiz

et al. 2024

High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XIII

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We present the design of a high-power suitable processing-head used for laser material processing with compact piezodriven kHz-range 3D beam steering in combination with a multiplexed output beam consisting of three different laser sources. The common beam consists of an 8-kW disc laser that is used to provide the bias-level of energy to preheat the work piece during welding or cutting close to the ablation threshold. The second laser is a MHz-switchable polarizationmodulated kW-class Yb-doped fiber amplifier, which in combination with a high-power suitable polarizer transfers the polarization-modulation into a fast switchable amplitude-modulation that is finally used for the material processing. Furthermore, for the purpose of process control during cutting and welding a spectrally shifted 10 W-class fs-pulsed laser is incorporated and used for Laser-induced breakdown spectroscopy (LIBS). Dynamic beam-steering and focusing in the range of several kHz at the output of the processing head is included utilizing a piezo-driven tip/tilt-mirror and a deformable mirror. Further details on the construction of the process head as well as on the different laser sources will be discussed in the presentation. Based on previous teaching of an AI-network with the obtained data from various parameter sweeps, such as camera images of the backscattered light, LIBS measurements and the inspection of the cutting edge or the welding seem, online process optimization shall be granted to improve process quality and cost-efficiency along with a decrease in yield during production.

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Beam shaping BrightLine Weld: latest application results

Cited by 10 publications

References 3 publications

Impact of laser beam shaping on weld pool and seam geometry in butt-joint welding with filler wire

Impact of laser beam shaping on weld pool and seam geometry in butt-joint welding with filler wire

Influence of ring-shaped laser beam during welding of AW-5083 and AW-6082

Design of a processing-head for AI-optimized welding and cutting

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